scanengine-3/tests/test_scan_geometry.py

"""core.scan_geometry vs the pre-refactor golden geometry fixtures,
plus structural invariants and travel-limit validation."""
import json
import math
from pathlib import Path

import pytest

from core.scan_geometry import (
    EtaEstimator, ScanGeometryError, StageLimits, build_plan, format_eta,
    validate_plan,
)

GOLDEN = Path(__file__).parent / "golden"


@pytest.fixture(scope="module")
def geometry():
    with open(GOLDEN / "geometry.json") as f:
        return json.load(f)


def _plan_from_case(case, consts):
    i = case["inputs"]
    return build_plan(
        float(i["XS"]), float(i["YS"]), float(i["XD"]), float(i["YD"]),
        int(i["num_angles"]), float(i["row_spacing"]),
        laser_freq_hz=consts["LASER_FREQ_HZ"],
        velocity_mm_s=consts["SCAN_VELOCITY_MM_S"],
        rotation_sign=consts["GR_ROTATION_SIGN"],
    )


def test_all_golden_cases_match(geometry):
    consts = geometry["constants"]
    for label, case in geometry["cases"].items():
        plan = _plan_from_case(case, consts)
        exp = case["params"]
        assert plan.x_start_nominal == exp["x_start_nominal"], label
        assert plan.y_start_nominal == exp["y_start_nominal"], label
        assert plan.x_delta_nominal == exp["x_delta_nominal"], label
        assert plan.y_delta_nominal == exp["y_delta_nominal"], label
        assert plan.row_spacing == exp["row_spacing"], label
        assert plan.n_angles == exp["num_angles"], label
        assert len(plan.per_angle) == len(exp["per_angle"]), label
        for pa, e in zip(plan.per_angle, exp["per_angle"], strict=True):
            assert pa.angle_deg == e["angle"], label
            assert pa.x_start == e["x_start"], label
            assert pa.x_delta == e["x_delta"], label
            assert pa.n_frames == e["n_frames"], label
            assert pa.n_rows == e["n_rows"], label
            assert pa.y_positions == e["y_positions"], label


def test_golden_error_cases_raise(geometry):
    consts = geometry["constants"]
    for case in geometry["error_cases"].values():
        with pytest.raises(ValueError):
            _plan_from_case(case, consts)


def test_zero_degree_bbox_equals_nominal_roi():
    plan = build_plan(10.0, 5.0, 20.0, 8.0, 1, 0.5,
                      laser_freq_hz=20000.0, velocity_mm_s=100.0)
    pa = plan.per_angle[0]
    assert pa.angle_deg == 0.0
    assert math.isclose(pa.x_start, 10.0)
    assert math.isclose(pa.x_delta, 20.0)
    assert math.isclose(pa.y_positions[0], 5.0)


def test_rotated_bbox_contains_all_roi_corners():
    plan = build_plan(30.0, 20.0, 24.0, 10.0, 7, 0.1,
                      laser_freq_hz=20000.0, velocity_mm_s=100.0)
    cy = 20.0 + 5.0
    corners = [(-12.0, -5.0), (12.0, -5.0), (-12.0, 5.0), (12.0, 5.0)]
    for pa in plan.per_angle:
        r = math.radians(pa.angle_deg)
        half_w = pa.x_delta / 2.0
        y_lo, y_hi = min(pa.y_positions), max(pa.y_positions)
        for dx, dy in corners:
            # ROI corner in the rotated frame
            rx = dx * math.cos(r) - dy * math.sin(r)
            ry = dx * math.sin(r) + dy * math.cos(r)
            assert abs(rx) <= half_w + 1e-9, pa.angle_deg
            # Row grid covers within one row-spacing at the edges
            assert y_lo - 0.1 - 1e-9 <= cy + ry <= y_hi + 0.1 + 1e-9, pa.angle_deg


def test_plus_minus_theta_symmetry():
    a = build_plan(10, 10, 20, 10, 5, 0.25, laser_freq_hz=20000.0,
                   velocity_mm_s=100.0, rotation_sign=1)
    b = build_plan(10, 10, 20, 10, 5, 0.25, laser_freq_hz=20000.0,
                   velocity_mm_s=100.0, rotation_sign=-1)
    for pa, pb in zip(a.per_angle, b.per_angle, strict=True):
        assert pa.angle_deg == -pb.angle_deg
        assert math.isclose(pa.x_delta, pb.x_delta)
        assert pa.n_rows == pb.n_rows
        assert pa.n_frames == pb.n_frames


def test_validate_plan_limit_violations():
    limits = StageLimits()
    ramp, buf = 100.0**2 / (2 * 1500.0), 1.0

    ok = build_plan(20.0, 10.0, 40.0, 30.0, 3, 0.25,
                    laser_freq_hz=20000.0, velocity_mm_s=100.0)
    validate_plan(ok, ramp, buf, limits)  # must not raise

    too_left = build_plan(2.0, 10.0, 40.0, 30.0, 1, 0.25,
                          laser_freq_hz=20000.0, velocity_mm_s=100.0)
    with pytest.raises(ScanGeometryError, match="pre-ramp start"):
        validate_plan(too_left, ramp, buf, limits)

    too_right = build_plan(80.0, 10.0, 40.0, 30.0, 1, 0.25,
                           laser_freq_hz=20000.0, velocity_mm_s=100.0)
    with pytest.raises(ScanGeometryError, match="run-off end"):
        validate_plan(too_right, ramp, buf, limits)

    too_low = build_plan(30.0, -5.0, 40.0, 30.0, 1, 0.25,
                         laser_freq_hz=20000.0, velocity_mm_s=100.0)
    with pytest.raises(ScanGeometryError, match="Y axis minimum"):
        validate_plan(too_low, ramp, buf, limits)

    too_high = build_plan(30.0, 60.0, 40.0, 30.0, 1, 0.25,
                          laser_freq_hz=20000.0, velocity_mm_s=100.0)
    with pytest.raises(ScanGeometryError, match="Y axis maximum"):
        validate_plan(too_high, ramp, buf, limits)


def test_format_eta():
    assert format_eta(-3) == "0s"
    assert format_eta(42) == "42s"
    assert format_eta(90) == "1m 30s"
    assert format_eta(3720) == "1h 02m"


def test_eta_estimator_rolls_and_resets_on_angle_change():
    eta = EtaEstimator(window=3)
    assert eta.eta_secs(5) is None
    t = 100.0
    for dur in (2.0, 4.0, 6.0, 8.0):
        eta.row_started(now=t)
        eta.row_finished(angle_idx=1, now=t + dur)
        t += dur
    # window=3 keeps [4, 6, 8] → avg 6
    assert eta.eta_secs(2) == pytest.approx(12.0)
    # angle change wipes history
    eta.row_started(now=t)
    eta.row_finished(angle_idx=2, now=t + 10.0)
    assert eta.eta_secs(3) == pytest.approx(30.0)